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SpaceX’s orbital Starship launch debut may be pushed to 2022 by slow FAA reviews
In a rare sign of material progress, SpaceX and the FAA have finally released what is known as a draft environmental assessment (EA) of the company’s South Texas Starship launch plans.
Set to be the largest and most powerful rocket in spaceflight history when it first begins orbital launches, the process of acquiring permission to launch Starship and its Super Heavy booster out of the wetlands of the South Texas coast was never going to be easy. The Boca Chica site SpaceX ultimately settled on for its first private launch facilities – initially meant for Falcon 9 and Falcon Heavy but later dedicated to BFR (now Starship) – is simultaneously surrounded by sensitive coastal habitats populated by several threatened or endangered species and situated mere miles as the crow flies from a city whose temporary population oscillates from a few thousand to tens of thousands.
Reception and analysis of the draft and its timing have been mixed. On one hand, SpaceX’s draft EA – completed with oversight from the FAA and help from the US Fish and Wildlife Service (USFWS) – gives a number of reasons for optimism. In a sign that SpaceX is taking a pragmatic approach to the inevitable environmental review and launch license approval hurdles standing in front of orbital South Texas Starship launches, the company has actually pursued what is known as a “programmatic environmental assessment” (PEA).
Most importantly, that means that SpaceX’s Starbase PEA – if approved – will be more like a foundation or stepping stone that should make it easier to start small and methodically expand the scope and nature of the company’s plans for Boca Chica. Along those lines, as part of Starbase’s first dedicated environmental assessment, SpaceX has proposed a maximum of 23 flight operations annually while Starship is still in the development phase, including up to 20 suborbital Starship test flights and 3 orbital launches (or Super Heavy hops). Once SpaceX has worked out enough kinks for slightly more confident Starship operations, the company would enter an “operational phase” that would allow for as many as five suborbital Starship launches and five orbital Starship launches, as well as ship and booster landings back on land after all 10 possible launches.
In other words, SpaceX’s initial draft PEA is extremely conservative, requesting permission for what amounts to a bare minimum concept of operations for orbital Starship launches. At a maximum of 3-5 orbital launches per year, a PEA and subsequent launch license approved as-is would likely give SpaceX just enough slack to perform basic Earth orbit launches and no more than one or two orbital refilling tests per year. However, as an example, a five-launch maximum would almost entirely prevent SpaceX from launching Starship to Mars, the Moon, and maybe even high-energy Earth orbits without using all of its annual launch allotments on a single mission.
Perhaps most importantly, the draft PEA as proposed would unequivocally prevent SpaceX from performing the NASA Human Lander System (HLS) Moon landings it received an almost $3 billion contract to complete. Each HLS Starship Moon landing is expected to require anywhere from 10-16 launches to deliver a depot ship, HLS lander, and ~1200 tons of propellant to orbit. However, in terms of SpaceX’s prospects of developing Starship as quickly as possible, that’s actually a good thing. Above all else, SpaceX’s slimmed-down draft PEA should be far easier for the FAA to approve than a PEA pursuing permission for Starship’s ultimate ambitions – dozens to hundreds of launches annually – from the beginning. In theory, with this barebones PEA approved, SpaceX would then be able to build off the foundation with additional environmental assessments – like, for example, of expanding Starship’s maximum launch cadence.
Of course, SpaceX first needs the FAA turn this first draft PEA into a favorable environmental assessment (not a guarantee) before any of the above starts to matter. Based on the content of the draft itself and associated appendixes, SpaceX appears to have a decent shot at receiving a “finding of no significant impact (FONSI)” or “mitigated FONSI” determination. However, SpaceX began the process of creating that draft as far back as mid-2020, followed by an FAA announcement in November 2020. The implication is that the FAA managed to drag out a draft release process that some have estimated should have taken 3-4 months into an arduous 10-15 month ordeal.
Combined with the uphill battle it’s starting to look like SpaceX will have to wage for an orbital Starship launch license in South Texas, it’s looking increasingly likely that Starship, Super Heavy, and Starbase will be technically ready for orbital launch tests well before the FAA is ready to approve or license them. Barring delays, the public now has until mid-October to read and comment on SpaceX’s draft PEA, after which the FAA and SpaceX will review those comments and hopefully turn the draft into a completed review. Even if the FAA were to somehow take just two months to return a best-case FONSI, clearing Starbase of environmental launch hurdles, it’s hard to imagine that the agency could then turn around and approve an orbital Starship launch license – or even a one-off experimental permit – in the last few weeks of 2021.
Ultimately, that means that nothing short of a minor miracle is likely to prevent the FAA’s environmental review and licensing delays from directly delaying Starship’s orbital launch debut. There is at least a chance that Starship, Super Heavy, and Starbase’s orbital launch site wont be ready for orbital launches by the end of the year, but it’s increasingly difficult to imagine that all three won’t be proof tested, qualified, and ready for action just a month or two from now. For the time being, we’ll just have to wait and see where the cards fall.
Elon Musk
Tesla reveals Optimus Academy, where robots teach themselves
Tesla has begun building production quality Optimus robots in Fremont and revealed its training plan.
Tesla has started building Optimus on the high volume line it set up inside its Fremont factory, and the company says the robots coming off it are the first that meet the bar for a real product. “The bots coming off this line are the first production-quality bots that we have manufactured,” Tesla wrote in its third quarter shareholder letter, adding that it has “proven that the current manufacturing process for Optimus is suitable for a commercial product.”
The line sits in space that built the Model S and Model X until this spring. Tesla cleared the old vehicle line in 46 days, as Teslarati reported in July, to make room for robot production sized for one million units a year. On Wednesday’s earnings call, Elon Musk said most of the equipment for that capacity is already in Fremont, with output set to climb toward roughly 20,000 robots a week as the line ramps.
Musk described the ramp as a classic S curve. “The growth of Optimus is an S curve, but the initial curve is a shallow slope,” he said. The team is now refining the robot’s AI, electromechanical design, reliability and service life, and Musk expects that work to be finished by the end of next year, when Tesla plans to start delivering Optimus to outside companies for dangerous, repetitive and around the clock jobs.
The most interesting part of the call was how Tesla plans to teach the robots. Its cars send real driving data back to the AI team from millions of vehicles, but Optimus has no fleet like that yet. “A big difference with Optimus versus the cars is we don’t have this vast fleet of cars from which we can gather training data,” Musk said. Tesla’s answer is an Optimus Academy, where 10,000 to 20,000 robots will practice a wide range of tasks and feed what they learn into the next version of the model. Every unit off the Fremont line becomes a source of that training data.
Smarter hardware is on the way too. Tesla plans to put its AI5 chip into Optimus next year, and Musk said a new Optimus video should arrive within one or two months showing the robot completing tasks driven by AI rather than preprogrammed motions. He took aim at rival humanoid demos that only run scripted routines, saying those would not hold up in the real world.
The supply chain is lining up behind the program. In September, Tesla certified Tuopu, Joyson and Sanhua as mass production partners for Optimus components. A far larger Optimus factory is also rising at Giga Texas, where drone footage from Joe Tegtmeyer showed the steel frame nearing completion, and Musk has pegged that plant’s long term target at 10 million robots a year.
Tesla executives also said Optimus production costs are trending toward the expected manufacturing cost of Cybercab, a sign the robot is being engineered for volume from the start. The hands remain the toughest piece of the design, a point Musk also made at the X Takeover event earlier this month, as Teslarati covered at the time, and that is where much of the current engineering effort is focused.
Elon Musk
The Starship moon landing number NASA and Elon Musk can’t agree on
Musk disputes NASA estimate of 22 Starship launches for Moon landing, predicting 6 to 8.
Elon Musk is disputing a new NASA safety panel estimate of how many Starship launches it will take to put astronauts on the Moon, saying the real number will be less than half the panel’s figure.
On Thursday, NASA’s Aerospace Safety Advisory Panel held its quarterly public meeting. Panel member Charlie Precourt, a former NASA astronaut, flagged the fueling process for SpaceX’s lunar lander as a major risk for Artemis IV, the mission planned to land a crew on the Moon in 2028. “We need to keep our eyes on numerous required fuelings for the lander,” Precourt said, according to Ars Technica. “I think the last estimate is around 22 flights.”
Ars Technica’s Eric Berger posted the comment on X, and Musk replied. “That’s way too high,” Musk wrote. “Actual number will be more like 6 to 8.”
The disagreement comes down to a basic problem with sending a ship as large as Starship to the Moon. Starship burns nearly all of its propellant just reaching Earth orbit, so it cannot continue on to the Moon without stopping for a refill. SpaceX’s answer is a gas station in space. First, a Starship that works as a storage tank, called a depot, is launched into orbit. Then a series of tanker Starships launch one at a time, dock with the depot and pump their leftover propellant into it. Once the depot is full, the lunar lander version of Starship launches, docks, fills up and heads for the Moon.
Every tanker trip is its own full rocket launch, which is why the count matters. More launches mean more time, more cost and more chances for something to go wrong before astronauts ever leave Earth. Berger estimated that even if SpaceX reaches twice weekly Starship launches by the end of 2027, filling a depot at the panel’s number would still take roughly three months.
How many tankers are needed depends mostly on how much propellant each one can carry to orbit and how much is lost along the way. Starship’s fuel and oxygen are stored at extremely cold temperatures, and some of it slowly boils off while waiting in orbit. More is lost in each transfer. NASA appears to be working from what Starship can lift today, while Musk’s range assumes a more capable rocket.
Musk has pushed back on higher counts before. In 2021, after a government document suggested 16 launches, he called that “extremely unlikely” and said eight tankers would be the most required.
Much of the answer depends on hardware SpaceX has not finished flying. As Teslarati noted earlier this year, the company plans to carry out the refueling process with its upgraded V3 Starship, and Precourt described Artemis IV as carrying “a large number of firsts.” He also praised NASA Administrator Jared Isaacman’s team for working to clear obstacles for both SpaceX and Blue Origin, whose Blue Moon lander does not rely on orbital refueling for its first mission.
Elon Musk
Tesla’s secretive “Project Crystal Sun” gets a big green light in Texas
Fort Bend County approved four incentive agreements Thursday for Tesla’s proposed $10.1 billion solar factory.
Fort Bend County commissioners on Thursday approved a package of tax incentives for Tesla’s proposed $10.1 billion solar cell factory near Needville, Texas, giving the company one of the last local approvals it needs before it decides where to build. All four Tesla agreements passed 4 to 0.
The votes covered a property tax abatement inside Reinvestment Zone No. 34, a Chapter 381 economic development agreement, a foreign trade zone non-objection paired with payments in lieu of certain taxes, and a separate payment in lieu of taxes “true up” agreement, according to agenda notes from the Fort Bend Commissioners Court meeting.
The project, known internally as “Project Crystal Sun,” would make solar cells and finished modules on roughly 3,000 acres near FM 762 and FM 1994, south of the Brazos River. As Teslarati reported when the filing first surfaced in August, Tesla’s application under the state’s JETI Act splits the investment into $1.5 billion in real property and $8.6 billion in equipment, with 9,712 permanent jobs projected by 2033 and commercial operations targeted for the first quarter of 2029. The plant would handle the full chain from ingot and wafer production through cell testing.
Inside Tesla’s secretive $10 Billion “Project Crystal Sun” filing
Thursday’s approval does not lock in the site. Tesla has told the Texas Comptroller it is still weighing other locations, and site selection adviser David Dennison told Lamar Consolidated ISD trustees in September that the race had narrowed to Fort Bend and one out of state rival with a “very compelling package,” according to the Houston Chronicle. Tesla hopes to decide before the end of 2026, and the incentives still need sign off from the Comptroller and the Governor’s office.
Local officials have now done nearly everything within their control. Commissioners created the reinvestment zone in an August 24 special meeting, with Interim County Judge Daniel Wong formally withdrawing himself over his engineering firm’s past work with Tesla. Lamar CISD trustees voted 7 to 0 on September 15 to advance a JETI agreement that would tax Tesla’s qualifying property at 50 percent of its value for maintenance and operations from 2029 through 2038.
The plant lines up with a target Elon Musk set on Tesla’s Q4 2025 earnings call in January, when he said the company would “work toward getting 100 GW a year of solar cell production, integrating across the entire supply chain from raw materials all the way to finished solar panels.” In March, Tesla was reported to be negotiating a $2.9 billion purchase of Chinese solar manufacturing equipment bound for Texas. The Houston area already hosts Tesla’s Megafactory in Brookshire, where Megapack 3 production has started. Tesla said on its Q3 call that Megapack supply for 2027 is nearly sold out, and Musk wrote on X Thursday that the company is “increasing production of Megapacks as much as possible,” as demand from data centers climbs.
Tesla reveals Optimus Academy, where robots teach themselves
The Starship moon landing number NASA and Elon Musk can’t agree on
